Connection box assembly method

ABSTRACT

A method for assembling an electrical connection box. The method may include the steps of selecting a connection box having at least one receiver, selecting an assembly comprising an electrical fixture and at least one anchor, and securing the assembly to the connection box by inserting the at least one anchor within the first receiver. The at least one receiver may include a first engagement mechanism designed to engage a second engagement mechanism included as part of the at least one anchor.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.10/435,716 filed May 8, 2003 and entitled QUICK ASSEMBLING ELECTRICALCONNECTION BOX APPARATUS AND METHOD, which is a continuation of U.S.Pat. No. 6,609,927 issued Aug. 26, 2003, which claims the benefit ofU.S. Provisional Patent Application Ser. No. 60/297,823 filed Jun. 12,2001 and U.S. Provisional Patent Application Ser. No. 60/273,803 filedon Mar. 6, 2001.

BACKGROUND

1. The Field of the Invention

This invention relates to fixture anchoring and, more particularly, tonovel systems and methods for facilitating connection box assembly.

2. The Background Art

Manually installing screws or other fasteners is often time consuming.Additionally, in certain installations, the installer must employ his orher hands to hold several components as well as rotate a tooltransferring rotation to a screw or other type of fastener. Maintainingall of the components in proper alignment is often difficult andrequires skill. In any case, the complexity slows the installationprocess.

Power tools may simplify the installation process by providing themotion (e.g. rotation) necessary to advance or install a fastener. Thepower tool must, however, be held and positioned in a manner similar toa manual tool. Thus, the use of power tools may not significantly lessenthe demands on the installer.

An electrical connection box assembly is one example of a time consumingfastener installation. Once an electrical fixture has been wired, thefixture is typically secured inside a connection box. Securement of theelectrical fixture to the connection box often involves the installationof multiple screws. These screws are generally over an inch long and arerelatively finely threaded. The length of the screws may be selected toaccommodate various connection box placements and wall panelingthicknesses. To complete a conventional electrical connection boxassembly, a face plate is secured to the fixture by another screw.Similar problems may be encountered in the installation of connectionsboxes used for a wide variety of devices and systems, including withoutlimitation telephone, stereo, computer network, information systems,cable television system, and security systems fixtures.

The installation of the connection box screws requires an installerconcurrently to hold a fixture, maintain screw alignment, and providerotation to the screw. Often it is difficult to initiate engagementbetween the screw and the receiving hole. Such difficulty typicallyarises because the receiving hole may be obscured by the wall panelingor recessed into the wall. Once the screw is in engagement with thereceiving hole, the time consuming and often laborious task of advancingthe finely threaded screw remains.

Face plate screws and other securement devices may be unsightly as wellas time consuming and laborious to install. Screws used to secure faceplates to connection boxes and fixtures are typically painted and are,therefore, exposed to chipping, tarnishing, wear, and oxidation. Incertain applications, it may be desirable to use a snap-on face plate toprovide fast securement without the use of screws to provide securement.

Fixture installation may consume a large portion of an electrician'stime budget for any given project. If the amount of time needed toinstall electrical fixtures were reduced, both the installer and thefinancier (e.g. home owner, developer, or the like) may realize largeeconomic rewards.

Attempts have been made to provide quick assembling connection boxes andfixture assemblies. Quick assembling devices typically involve at leastsome rotation of the fixture screws and, therefore, require the use oftools for installation. Often these devices are limited in how well theyare able to engage the threads of the fixture screws. Thus, such devicesmay not provide a reliable and solid securement between the fixture andconnection box.

Typical screwless face plates require additional components to enablesecurement to the electrical fixture. These additional componentsincrease manufacturing cost as well as installation time.

What is needed is an anchor that provides a strong and reliablesecurement between a fixture and associated connection box. Such ananchor would also provide for quick and simple installation thereof.Additionally, a screwless face plate that requires no additionalcomponents to accomplish a reliable securement would be an advancementin the art. Such a connection box assembly would greatly reduce thetime, skill level, and effort required to assemble and completeconnection box installation (e.g. electrical fixture installation or thelike).

BRIEF SUMMARY AND OBJECTS OF THE INVENTION

In view of the foregoing, it is a primary object of the presentinvention to provide an apparatus and method requiring minimal time,effort, and skill to install.

It is a further object of the invention to provide a connection boxapparatus and method that may be installed without screw rotation.

Consistent with the foregoing objects, and in accordance with theinvention as embodied and broadly described herein, a method andapparatus are disclosed. An embodiment in accordance with the presentinvention may provide an apparatus for securing a fixture to aconnection box. In a factory manufacturing process an anchor may besecured to a fixture. In one embodiment, the anchor is secured to thefixture by a releasable fastener. The anchor may have an engagementmechanism formed therewith.

A connection box may be provided to house lines or wires originiatingfrom a signal source to terminate therein. The lines may provide aconnection for the fixture. A receiver may be associated with theconnection box. The receiver may have an engagement mechanism formed toreceive and retain the engagement mechanism of the anchor. Thus, theanchor and receiver may be intermediaries in the securement of thefixture to the connection box.

In certain applications, screws and other securement devices may beunsightly. In these applications it may be desirable to provide asnap-on face plate to provide fast securement without the use of screws.Face plates are often secured to fixtures to cover and hide the wiringand access holes therebehind. Face plates in accordance with the presentinvention may have engagement prongs. These prongs may be insertedthrough apertures in a corresponding fixture to maintain the face platealigned securely thereagainst.

In selected embodiments in accordance with the present invention, aninstaller may first connect a fixture to the lines or wires housed in aconnection box. A face plate may be installed by simply pressing theengagement prongs through the appropriate apertures in the fixture. Oncea fixture has been connected to the lines and a face plate applied, thefixture may be secured to the connection box by inserting one or more ofthe attached anchors into corresponding receivers associated with theconnection box. The anchors may be inserted a selected distance into thereceivers until the face plate is properly positioned. Insertion of ananchor into a receiver may be accomplished without the aid of tools.

The method of engagement between the engagement mechanism of thereceiver and that of the anchor may be selected to provide a fast, cleansecurement. In selected embodiments, the engagement mechanism of thereceiver may be a barb configured to engage a series of teeth providedas part of the engagement mechanism of the anchor. In other embodiments,the engagement mechanism of the anchor may be a barb configured toengage a series of teeth provided as part of the engagement mechanism ofthe receiver. The engagement between the anchor and receiver may providea single or multiple locking positions.

By applying embodiments in accordance with the present invention, afixture may be secured to a connection box in a comparatively shortamount of time. Embodiments in accordance with the present invention maybe particularly advantageous when it is desirable to preserve theability to remove the fixture from the connection box. For example, anelectrician or computer network technician may need to remove a fixtureto gain access to the lines or wiring tucked therebehind. In such asituation, the face plate may be “popped” off and the fasteners holdingthe fixture to the anchors may be released, thus freeing the fixture.Each anchor may maintain engagement with its corresponding receiver.After the revisions are complete the fixture may once again be securedto the anchors by the installation of the fastener previously released.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objects and features of the present inventionwill become more fully apparent from the following description, taken inconjunction with the accompanying drawings. Understanding that thesedrawings depict only typical embodiments of the invention and are,therefore, not to be considered limiting of its scope, the inventionwill be described with additional specificity and detail through use ofthe accompanying drawings in which:

FIG. 1 is an exploded perspective view of a connection box assembly inaccordance with the present invention;

FIG. 2 is a perspective view of one embodiment of an anchor inaccordance with the present invention;

FIG. 3 is a perspective view of an alternative embodiment of an anchorin accordance with the present invention;

FIG. 4 is a perspective view of another alternative embodiment of ananchor in accordance with the present invention;

FIG. 5 is a top cross-sectional view of an engagement between an anchorand receiver in accordance with the present invention;

FIG. 6 is a front cross-sectional view of the engagement of FIG. 5;

FIG. 7 is a partial perspective view of an alternative embodiment of ananchor in accordance with the present invention;

FIG. 8 is a top cross-sectional view of an alternative engagementbetween an anchor and receiver in accordance with the present invention;

FIG. 9 is a top cross-sectional view of another alternative engagementbetween an anchor and receiver in accordance with the present invention;

FIG. 10 is a partial cutaway, perspective view of an application of aquick assembling connection box in accordance with the presentinvention;

FIG. 11 is a perspective view of a receiver in accordance with thepresent invention formed as part of a metal connection box;

FIG. 12 is an exploded perspective view of an alternative embodiment ofa face plate and fixture assembly in accordance with the presentinvention;

FIG. 13 is a perspective view of a complete assembly prepared forinstallation in accordance with the present invention;

FIG. 14 is a partial perspective view of a face plate and fixtureassembly in accordance with the present invention;

FIG. 15 is a side cross-sectional view of a screwless face plateassembly using an adapter in accordance with the present invention;

FIG. 16 is a side cross-sectional view of an engagement prong inaccordance with the present invention;

FIG. 17 is a perspective view of an engagement prong in accordance withthe present invention;

FIG. 18 is a perspective view of a fixture with a flange modified inaccordance with the present invention;

FIG. 19 is a perspective view of an alternative embodiment of ascrewless face plate in accordance with the present invention to engagethe fixture of FIG. 18;

FIG. 20 is a side cross-sectional view of an engagement between thefixture of FIG. 18 and the screwless face plate of FIG. 19;

FIG. 21 is a partial perspective view of alternative engagement betweena screwless face plate and an fixture in accordance with the presentinvention;

FIG. 22 is a cutaway, partial perspective view of alternative engagementbetween a screwless face plate and a fixture in accordance with thepresent invention;

FIG. 23 is a perspective view of a fixture with an adapter in accordancewith the present invention; and

FIG. 24 is a side cross-sectional view of a fixture with an adapter inaccordance with the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

It will be readily understood that the connection box assemblies of thepresent invention, as generally described and illustrated in the Figuresherein, could be arranged and designed in a wide variety of differentconfigurations. Thus, the description herein is not intended to limitthe scope of the invention, but is merely representative of certainpresently preferred embodiments of devices and systems in accordancewith the invention. Those of ordinary skill in the art will, of course,appreciate that various modifications to the details herein may easilybe made without departing from the essential characteristics of theinvention, as described. Thus, the following information is intendedonly by way of example, and simply illustrates certain presentlypreferred embodiments consistent with the invention.

Referring to FIG. 1, in discussing the Figures, it may be advantageousto establish a reliable coordinate system to aid in the description ofseveral of the embodiments in accordance with the present invention.Coordinate axes 11 may be defined by longitudinal 11 a, lateral 11 b,and transverse directions 11 c substantially orthogonal to one another.

A connection box assembly 10 in accordance with the present inventionmay provide an apparatus for securing a fixture 12 to a connection box14. In a factory manufacturing process, an anchor 16 may be secured tothe fixture 12. The connection box 14 to which the fixture 12 is to besecured may have a receiver 18 associated therewith for admitting andretaining the anchor 16. Thus, the anchor 16 and receiver 18 may beintermediaries in the securement of the fixture 12 to the connection box14. A face plate 20 may be provided to cover and hide the wiring andaccess holes therebehind.

A fixture 12 may be any suitable piece for which securement is desired.For example, a fixture 12 may be a power receptacle, power switch, lightfixture, telephone jack, network jack, cable connector, stereo systemconnector, information system connector, or any other unit 12 for whichpermanent or removable securement to a connection box 14 may be desired.In a similar manner, the connection box 14 may be any box to which afixture 12 may be secured. A connection box 14 may be constructed of anysuitable material. Suitable materials may include without limitationmetals, polymers, composites, and the like. Additionally, a connectionbox 14, in accordance with the present invention, may be of any suitablesize. For example, a connection box 14 may be a single gang, doublegang, triple gang, quadruple gang, quintuple gang, or the like. Theconcepts presented herein are illustrated as a single gang box, however,the principles and concepts may easily be expanded to multiple-gangconnection boxes.

Embodiments, in accordance with the present invention may beparticularly well suited to assemblies that may be assembled in thefield (i.e. not in a factory). Such field assemblies need not be limitedto connection box assemblies 10. Embodiments in accordance with thepresent invention may provide convenience and ease of assembly in thefield where less than perfect conditions are often encountered.

An anchor 16 in accordance with the present invention may beconstructed, formed, machined, extruded, molded, cast, or otherwise madefrom any suitable material. Suitable materials may include withoutlimitation metals, polymers, composites, or the like. For example, incertain embodiments, an anchor 16 may be formed of a polymer in amolding process.

An anchor 16 may be secured to a fixture 12 in any suitable manner. Incertain embodiments, an anchor 16 may be secured to a fixture 12 by afastener 22 such as a bolt, rivet, screw, engagement prong, engagementhook, or the like. In other embodiments, an anchor 16 may be glued orotherwise bonded to a fixture 12. Additionally, an anchor 16 may beformed as an integral part of the fixture 12.

Each form of attachment between the anchor 16 and the fixture 12 mayhave particular advantages. In certain applications, such as theinstallation of power receptacles 12, switches 12, computer networkoutlets 12, cable television outlets 12, and the like an installer mayneed to remove a fixture 12 to gain access to something (e.g. wiring)tucked therebehind. In such a situation, screws 22 may provide an idealattachment between the anchor 16 and the fixture 12. The screws 22 maybe removed, thus freeing the fixture 12. The anchors 16 may maintainengagement with the connection box 14. After the revisions are completethe fixture 12 may once again be secured to the anchors 16 by theinsertion of the screws 22 previously removed.

In selected applications, multiple points of securement between afixture 12 and a connection box 14 may exist. In such situations, ananchor 16 in accordance with the present invention may be applied to allor a subset of the securement locations. For example, power receptacles12 and switches 12 are typically secured to connection boxes 14 by twoscrews spaced from each other in a longitudinal direction 11 a. Ananchor 16 a, 16 b may be applied to fasteners 22 a, 22 b respectively.Similarly, a connection box 14 may have multiple receivers 18 a, 18 b toengage both anchors 16 a, 16 b, respectively.

The method of engagement between a receiver 18 and an anchor 14 may beselected to provide a fast, clean securement. By so doing, the fixture12 may be secured to the connection box 14 in a minimum amount of time.For example, installers (e.g. electricians, network technicians, cabletelevision installers, and the like) spend a large portion of theirinstallation time screwing fixtures 12 to connection boxes 14. Incertain embodiments in accordance with the present invention, a fastener22 (e.g. screw 22) may be introduced to secure an anchor 16 to theappropriate locations on a fixture 12 by a manufacturing machine. Thus,the installation of the fastener 22 may be performed in ideal conditionswith proper alignment and fast tool speeds. In the field, when aninstaller installs the fixture 12, the time consuming screw installationno longer needs to be performed. An anchor 16 may simply be insertedinto a receiver 18.

The embodiments of the fixture 12, connection box 14, anchors 16 a, 16b, receivers 18 a, 18 b, and face plate 20, as illustrated in FIG. 1 maybe arranged and designed in a wide variety of different configurationsthat fall within the scope of the present invention. Thus, thedescription hereinabove is not intended to limit the scope of thepossible embodiments, but is merely representative of certain presentlypreferred embodiments of devices and systems in accordance with theinvention. The information is intended only by way of example.

Referring to FIG. 2, an anchor 16 in accordance with the presentinvention may have an engagement mechanism 24 configured to provide amechanical grip with a receiver 18. If an anchor 16 is to be secured toa fixture 12 by a bolt 22 or screw 22, a threaded aperture 26 may beformed therein. The threaded aperture 26 may extend completely or onlypartially through the anchor 16 in a transverse direction 11 c.

A length 28 of the engagement mechanism 24 may be selected to provide adesired number of engagement locations 30. In selected embodiments, eachengagement location 30 is a tooth 30. Additionally, the engagementlength 28 and the number of engagement locations 30 may be selected topermit insertion of the anchor 16 a desired distance into the receiver18. Thus, providing a desired alignment of the fixture 12 with respectto the connection box 14.

In selected embodiments, an anchor 14 in accordance with the presentinvention may include a spacer 32. The length 34 of the spacer 32 may beselected to provide additional control over the spacing of the fixture12 in relation to the connection box 14.

In certain embodiments, one end 36 of the anchor 16 may be formed topromote easy insertion into the receiver 18. For example, an end 36 maybe pointed, rounded, tapered, or otherwise formed.

An anchor 16 in accordance with the present invention may have anysuitable cross-section. For example, the cross-section may berectangular, circular, triangular, oval, an unconventional shape, or thelike. The cross-sectional shape of an anchor 16 may be selected toresist rotation about a transverse axis 11 c once installed inside areceiver 18. For example, an anchor 16 having a generally circularcross-section may have a key-way formed therein to correspond to a keyformed or located in the receiver 18.

The shape and configuration of a receiver 18 may be selected to matchand complement the particular shape of a selected anchor 16. Forexample, if an anchor 16 having a rectangular cross section is desired,the receiver 18 may be formed to have a generally rectangular shape.Thus, the receiver 18 may admit the anchor 16 and hold the anchor 16securely without motion (e.g rotation about a transverse axis 11 c)therebetween.

Referring to FIG. 3, in certain embodiments, an anchor 16 may havemultiple sliding surfaces 38 to promote ease of insertion and properalignment. A recessed groove 40 may be formed in one or more surfaces 38of the anchor 16 to provide a location for disposition of an engagementmechanism 24. Such an engagement mechanism 24 may be recessed to reducethe risk of interfering with proper insertion of the anchor 16 into thereceiver 18.

Referring to FIG. 4, an anchor 16 may have a generally circularcross-section. In such an embodiment, the anchor may include a singleflat 42 or may include a plurality of flats 42 that provide a locationfor disposition of an engagement mechanism 24. The flats 42 may alsoprovide a location for a corresponding receiver 18 to engage the anchor16 to resist rotation about a transverse axis 11 c.

FIG. 4 also illustrates an alternative embodiment of a fastener 22 inaccordance with the present invention. Opposing engagement hooks 22 maybe shaped to promote insertion into a corresponding aperture in afixture 12. The engagement hooks 22 may be formed to engage an apertureof any suitable shape (e.g. circular, oval, triangular, or the like).The illustrated engagement hooks 22 have been formed in a shape to fit asquare aperture. A square aperture may provide a mechanism to resistrotation of the anchor 16 about a transverse axis 11 c with respect to acorresponding fixture 12. Engagement hooks 22 in accordance with thepresent invention may flex to allow an anchor 16 to be separated fromthe fixture 12 to which the anchor 16 is attached. Once separated, theanchor 16 and fixture 12 may be reattached by reinserting the engagementhooks 22 of the anchor 16 through the corresponding aperture in thefixture 12.

The embodiments of anchors 16, as illustrated in FIGS. 2-4 could bearranged and designed in a wide variety of different configurations thatfall within the scope of the present invention. Thus, the descriptionhereinabove is not intended to limit the scope of the possibleembodiments, but is merely representative of certain presently preferredembodiments of devices and systems in accordance with the invention. Theinformation is intended only by way of example and not by way oflimitation.

Referring to FIGS. 5-6 while continuing to refer generally to FIGS. 1-4,as discussed hereinabove, an anchor 16 in accordance with the presentinvention may have multiple sliding surfaces 38. The sliding surfaces 38may maintain proper alignment of the anchor 16 with respect to thereceiver 18.

In selected embodiments, a receiver 18 in accordance with the presentinvention may include an engagement mechanism 39. This engagementmechanism 39 may be configured to engage the engagement mechanism 24 ofan anchor 16. In selected embodiments, an engagement mechanism 39 maycomprise hooks 44 or barbs 44. These barbs 44 may extend from thereceiver 18 with a shape selected to engage the teeth 30 of the anchor16. The engagement of the hooks 44 and teeth 30 may be selected toprovide unidirectional motion so that an anchor 16 may be easilyinserted yet resist removal in a transverse direction 11 c. The numberof teeth 30 and the incremental distance 46 therebetween may be selectedto provide a continuum of possible locking positions between the anchor16 and the receiver 18.

Referring to FIGS. 7-8 while continuing to refer generally to FIGS. 1-6,in an alternative embodiment, an anchor 16 may include a single hook 44.In selected embodiments, an anchor 16 may include multiple hooks 44. Aflexible region 48 may permit a hook 44 to flex as it “clicks” or passesover the teeth 30 of a receiver 18. As discussed hereinabove and as bestshown in FIG. 8, the number of teeth 30 and the incremental distance 46therebetween may be selected to provide a continuum of possible lockingpositions between the anchor 16 and the receiver 18.

Referring to FIG. 9, in selected embodiments, the engagement between ananchor 16 and a receiver 18 may not be incremental, rather a singlelocking position may be defined. In such an embodiment, the anchor 16may be inserted into the receiver 18 until a lock 50 is activated. Inselected embodiments, a lock 50 may consist of a hook 44 secured on thedistal end of a flexible region 48. A stop 52 may provide a register tocorrectly position the anchor 16 with respect to the receiver 18. Whenthe anchor 16 is inserted to the stop 52, a hook 44 may engage anengagement location 30 of the receiver 18.

Referring to FIG. 10, the length 28 (see FIG. 2) of the engagementmechanism 24 may be selected to best match the particular application towhich the engagement mechanism 24 may be applied. For example, theinstallation of a light fixture 12 may be simplified by employing acomparatively long anchor 16 having a similarly long engagementmechanism 24. In such an application, two long anchors 16 may be securedto the fixture 12. The anchors 16 may be introduced into thecorresponding receivers 18 a distance sufficient to engage theengagement mechanisms 39 thereof. The anchors 16 may then hold thefixture 12 in place while the installer proceeds to connect thenecessary wires 54. Upon completion of the connecting of the wires 54,the fixture 12 may be pushed in a transverse direction 11 c until aproper position is achieved. Thus, the installer need not hold thefixture 12 while connecting wires 54 and tightening terminal screws 56.

Referring to FIG. 11, a receiver 18 may be associated with a connectionbox 14 in any suitable manner. In selected embodiments, the receiver 18may be formed as an integral part of the connection box 14. This formingmay be part of a molding process. That is, the receiver 18 may be moldedas part of the connection box 14 in its original forming process. FIG.11 illustrates an embodiment in which the receiver 18 is formed bystamping selected shapes from a metal connection box 14 and then bendingthe cut portions in a selected direction to form a guide 57 and anengagement mechanism 39. In an alternative embodiment, a receiver 18 maybe formed (e.g. molded, extruded, cast, machined, stamped, or the like)and then joined to the connection box 14. Such a joining may beaccomplished by bolting, screwing, welding, gluing, bonding, or thelike.

Referring to FIG. 12, connection boxes 14 are typically installed andwired before the installation of the wall paneling (e.g., ceilingpaneling and the like). Fixtures 12 and face plates 20 are typicallyinstalled after the installation of the wall paneling. The installationof wall paneling often involves the application of dry wall compound. Itis very common for clumps of dry wall compound to be inadvertentlyintroduced inside a previously installed connection box 14. Receivers 18in accordance with the present invention may be formed in a manner togreatly limit the adverse effects of misplaced dry wall compound.

For example, if dry wall compound were placed in the receiver entrance58, the receiver may be formed to have an open back exit 59. Thus,anchor 16 may be inserted into the receiver 18 and any clump of dry wallcompound may simply be pushed out the back 59 of the receiver 18. Theback 59 may be open to the exterior of the connection box 14. The back59 may also be configured to open to the interior of the connection box14. In such a configuration, a dry wall compound clump will be pushed tothe interior of the connection box 14 where it can do no harm.

Embodiments in accordance with the present invention may be applied toany unit 12 for which permanent or removable securement to a connectionbox 14 is desired. Data terminals such as phone jacks, network jacks,cable connections, and the like may not have a fixture 12 associatedtherewith. These applications may deliver a transmission line to a jack60 or connector 60 mounted directly in a face plate 20. The face plate20 provides the structure and support for the jack 60, and indeed mayprovide many of the same functions as a fixture 12. Typically these faceplates have been secured directly to a corresponding connection box bymultiple screws. Installation of such screws presents difficultiessimilar to those encountered in the installation of fixtures 12.

FIG. 12 illustrates one embodiment of a jack connection box assembly 10in accordance with the present invention. Interface members 62 a, 62 bmay provide an interface between a face plate 20 and anchors 16 a, 16 b.In selected embodiments, the interface members 62 may include anaperture 64 to accommodate securement of an anchor 16. Additionalapertures 66 may provide locations for the face plate 20 to engage theinterface members 62. In certain embodiments, extensions 68 or “dogears” 68 may be incorporated to hold each interface member 62 flush withthe wall paneling.

The interface members 62 may be formed in any suitable shape forproviding adequate engagement between an anchor 16 and a face plate 20.In one embodiment, the interface members 62 are generally flat pieceshaving multiple apertures 64, 66 and extensions 68. The interfacemembers 62 may be constructed of any suitable material. In selectedembodiments, interface members 62 may be formed by stamping sheet metal.In alternative embodiments, interface members 62 may be molded from apolymer, a composite, or the like.

Referring to FIGS. 13-15, as discussed hereinabove, after theinstallation of a fixture 12, a face plate 20 is typically securedthereto to hide the under workings from view. Conventional face plates20 are often secured by at least one screw. Screws and other securementdevices may be unsightly. Screws used to secure face plates 20 toreceptacles and switches are typically painted and are, therefore,exposed to chipping, tarnishing, wear, oxidation, and the like. In suchapplications, it may be desirable to provide a snap-on assembly toprovide fast securement of a face plate 20 without the use of screws.

FIGS. 13-15 illustrate one embodiment of a screwless face plate 20 inaccordance with the present invention. In selected embodiments, a faceplate 20 may include engagement prongs 70. The engagement prongs 70 mayengage a fixture 12 and maintain the face plate 20 aligned and securedthereto. Thus, once a face plate 20 has been attached, a completefixture 12 assembly may be quickly and easily wired and then secured toa corresponding connection box 14.

Selected fixtures 12 in accordance with the present invention mayinclude flanges 72. Flanges 72 a, 72 b may extend away from a main body74 of a fixture 12 in a longitudinal direction 11 a. In selectedembodiments, the flanges 72 may include an aperture 64 to accommodatethe securement of an anchor 16. Additional apertures 66 may providelocations for the engagement prongs 70 of the face plate 20 to engagethe flanges 72. In certain embodiments, extensions 68 or “dog ears” 68may be selected to hold the fixture 12 flush with the wall paneling.

Engagement prongs 70 in accordance with the present invention may beformed to have multiple hooks 76 a, 76 b, 76 c, 76 d. The hooks 76 maybe secured to the face plate 20 by flexible necks 78 a, 78 b, 78 c, 78d, respectively. A flex clearance 80 may be provided between the hooks76 so that as the prong 70 is inserted through an aperture 66, the hooks76 may deflect toward each other, thus, effectively reducing thediameter of the prong 70. Once the prong 70 has passed through theaperture 66, the hooks 76 may return to their neutral position andengage the edges of the aperture 66.

Referring to FIGS. 16 and 17, in selected embodiments, the hooks 76 maybe shaped to release at a desired removal loading, thus, once the faceplate 20 is removed, the face plate 20 may be used again. For example,the hooks 76 may be provided with an inside taper 82. The inside taper82 may allow each hook 76 to gradually flex and bend towards the flexclearance 80 as the face plate 20 is pulled away from the fixture 12 sothat the effective diameter of the engagement prong 70 may be reducedand the prong 70 may be removed from the aperture 66. In an alternativeembodiment, a face plate 20 in accordance with the present invention maybe removed by applying sufficient force to fail the hooks 66.

A screwless face plate 20 in accordance with the present invention maybe formed of any suitable material. This material may be selected basedon several characteristics including cost, aesthetics, dielectricconstant, thermal capacity, strength, toughness, flexibility,formability, and the like.

Engagement prongs 70 in accordance with the present invention may haveany suitable configuration. The number of prongs 70 may range from oneto several and be selected to provide a balanced securement between aface plate 20 and a fixture 12. The number of hooks 76 making up eachprong 70 may also range from one to several depending on a desiredengagement strength, ease of manufacture, ease of installation, ease ofremoval, and the like. In certain embodiments, the engagement strengthmay be balanced with a desired release loading. The general shape orcontour of the prongs 70 may also be selected to provide a desiredengagement strength, ease of manufacture, ease of installation, ease ofremoval, and the like.

Referring to FIGS. 18-20, alternative embodiments in accordance with thepresent invention may employ alternative methods for securing ascrewless face plate 20 to a fixture 12. In one alternative embodiment,a flange 72 a of a fixture 12 may have an engagement lip 84 formedtherein. A extension 86 may be formed in association with acorresponding face plate 20. The engagement lip 84 may be configured tofit behind the extension 86 to hold the upper portion of the face plate20 to the flange 72 a.

An aperture 66 may be formed in a flange 72 b of the fixture 12. Acorresponding engagement prong 70 may be formed in association with theface plate 20. The prong 70 illustrated in FIGS. 18-19 is an example ofa single hook, rectangular prong 70. The aperture 66 may be shaped tocorrespond to the design of the prong 70. In selected embodiments, thelip 84/extension 86 and aperture 66/prong 70 combinations may cooperateto secure the face plate 20 to the fixture 12. Such an embodiment may beinstalled by first inserting the lip 84 behind the extension 86 and thenrotating the face plate 20 down against the fixture 12 until theprong(s) 70 may be inserted into the corresponding aperture(s) 66. Theprong 70 engagement may provide a tie to resist the tendency of the lip84 to disengage from the extension 86.

An engagement lip 84 in accordance with the present invention may bedivided into multiple engagement lips 84. In selected embodiments, anupper flange 72 a may be formed into two lips 84 a, 84 b. The lips 84 a,84 b may be separated by a notch 88. A stop 90 may be formed as part ofa corresponding extension 86. The stop 90 may fit into the notch 88 toprevent lateral motion between the upper flange 72 a and the face plate20.

In certain embodiments, ends 92 may form an enclosure 94 in combinationwith an extension 86 and corresponding face plate 20. The ends 92 mayfunction to laterally retain the lip 84 of a flange 72 a, whenassembled.

In selected embodiments, a face plate 20 in accordance with the presentinvention may have an access notch 96. In certain embodiments, an accessnotch 96 may simply provide a hold to permit the application of force to“pop” a face plate 20 from a corresponding fixture 12. In alternativeembodiments, the access notch 96 may provide access behind the faceplate 20 to a slender tool. The slender tool may then be used to assistin the release of an engagement prong 70.

Referring to FIG. 21, an alternative embodiment of an engagement betweena screwless face plate 20 and a fixture 12 may involve the engagement ofan edge 98 of the flanges 72 of the fixture 12. One or more of theengagement prongs 70 of the face plate 20 may be configured to engage anedge 98. In selected embodiments, the prongs 70 may be formed to have ahook 76 and a flexible neck 78. In certain embodiments, a flange 72 mayinclude a formation 100 to resist motion in a longitudinal direction 11a of a face plate 70 with respect thereto. Such a formation 100 may beformed by bending, cutting and bending, notching, or similarly modifyingthe edge 98 to resist sliding of a prong 70 therealong in a longitudinaldirection 11 a.

Referring to FIG. 22, an alternative embodiment of an engagement betweena screwless face plate 20 and a fixture 12 may involve an engagementbetween a face plate 20 and an interface 104 of a fixture 12. Typically,the interface 104 of a fixture 12 extends a selected distance 106 toprovide a flush joint with a face plate 20. That is, the interface 104extends to provide a facing 108 that may be substantially coplanar witha surface 110 of the face plate 20, thereby improving aesthetic appeal.The area of the facing 108 may be selected to correspond to a selectedinterface 104. Power outlet plugs 104 provide a relatively large surfacearea. In contrast, switches 104 typically have a toggle central unit anda thin border providing minimal surrounding facing 108.

The extension distance 106 of the electrical interface 104 provides thesurface (substantially perpendicular to the facing 108) of an edge 102.An edge 112 of an aperture 114 (the aperture 114 may admit the interface104 throUgh the face plate 20) may be configured to engage the edge 102of the interface 104. This engagement may be of any suitable form. Forexample, the engagement may involve any suitable combination of tabs,recesses, hooks, shoulders, and the like.

In selected embodiments, the engagement between the edges 102, 112 mayinvolve tabs 116 formed on the face plate 20 and recesses 118 formed inthe interface 104. The shape, number, and location of thesecorresponding pairs may be selected to provide a desired engagementstrength, magnitude, and balance. Engagement strength refers to theamount of force required to apply and secure the face plate 20 to thefixture 12 or, alternatively, the force required to separate the faceplate 20 from the fixture 12. The engagement strength may be selected toprovide fast “snap-on” assembly without risking inadvertent removal ofthe face plate 20 and possible electrical shock resulting therefrom.

Referring to FIGS. 23 and 24, an adapter 120 may be provided to convertor retrofit a conventional fixture 12 to receive a screwless face plate20. In selected embodiments, an adapter 120 in accordance with thepresent invention may include an aperture 122 corresponding to aperture64 of a flange 72. A fastener 22 used to secure an anchor 16 to afixture 12 may also pass through the aperture 122 to hold an adapter 120in place against the flange 72. The adapter 120 may extend to provideapertures 68 for admitting the prongs 70 of a corresponding face plate20. In this manner, a snap-on, screwless face plate 20 may beretrofitted to typical power receptacles and switches.

An adapter 120 in accordance with the present invention may be formed ofany suitable material. In selected embodiments, the adapter 120 may beformed by stamping sheet metal. In an alternative embodiment, theadapter 120 may be a molded polymer or composite.

From the above discussion, it will be appreciated that the presentinvention provides an apparatus and method for fast and simpleconnection box assembly without screw rotation and the time associatedtherewith. An embodiment in accordance with the present invention mayprovide an apparatus for securing a fixture to a connection box. In afactory manufacturing process an anchor may be secured to a fixture. Theanchor may have an engagement mechanism formed therewith. A connectionbox may be provided to house wires proceeding from a source to terminatetherein. A receiver may be associated with the connection box. Thereceiver may have an engagement mechanism formed to receive and retainthe engagement mechanism of the anchor. Thus, the anchor and receivermay be intermediaries in the securement of the fixture to the connectionbox. Face plates in accordance with the present invention may haveengagement prongs. These prongs may be inserted through apertures in acorresponding fixture to maintain the face plate aligned securelythereagainst. A face plate may be installed by simply pressing theengagement prongs through the appropriate apertures in the fixture. Oncea fixture has been wired and a face plate applied thereto, the resultingassembly may be secured to the connection box by inserting one or moreof the attached anchors into corresponding receivers associated with theconnection box. The anchor may be inserted a depth into the receiverselected to properly position the face plate. Insertion of an anchorinto a receiver may be accomplished without the aid of tools.

The present invention may be embodied in other specific forms withoutdeparting from its spirit or essential characteristics. The describedembodiments are to be considered in all respects only as illustrative,and not restrictive. The scope of the invention is, therefore, indicatedby the appended claims, rather than by the foregoing description. Allchanges that come within the meaning and range of equivalency of theclaims are to be embraced within their scope.

1-20. (canceled)
 21. A fixture configured to be secured to a connectionbox and be at least partially covered by a face plate, the fixturecomprising: a main body; and at least one flange extending from the mainbody, the at least one flange defining a fixture securement apertureconfigured to receive a fastener for securing the fixture to theconnection box and defining at least one face plate engagement apertureconfigured to receive a prong extending from the face plate in a mannerthat secures the face plate to the fixture.
 22. The fixture of claim 21wherein the fixture is a power receptacle and the main body includes afirst electrical socket and a second electrical socket.
 23. The fixtureof claim 21 wherein the at least one flange comprises a first flangeextending from a first end of the main body and a second flangeextending from an opposite second end of the main body.
 24. The fixtureof claim 21 wherein the at least one flange comprises at least oneextension configured to extend beyond an outer periphery of theconnection box and hold the fixture flush with a wall to which theconnection box is mounted.
 25. The fixture of claim 21 wherein the atleast one face plate engagement aperture comprises a first face plateengagement aperture and a second face plate engagement aperture.
 26. Thefixture of claim 25 wherein the first face plate engagement aperture andthe second face plate engagement aperture are circular in shape.
 27. Thefixture of claim 25 wherein the fixture securement aperture is locatedbetween the first face plate engagement aperture and a second face plateengagement aperture.
 28. A face plate configured to at least partiallycover a fixture having a flange used for securing the fixture to aconnection box, the face plate comprising: a body having a front faceand an opposite rear face; and at least one prong outwardly extendingfrom the rear face of the body, the at least one prong configured to beinserted into an aperture in the flange of the fixture to secure theface plate to the fixture.
 29. The face plate of claim 28 wherein atleast a portion of the at least one prong is configured to reduce indiameter while passing through the aperture in the flange of the fixtureand to increase in diameter after passing through the aperture to securethe face plate to the fixture.
 30. The face plate of claim 28 whereinthe at least one prong is configured to engage substantially theentirety of a perimeter of the aperture in the flange of the fixture tosecure the face plate to the fixture.
 31. The face plate of claim 28wherein the at least one prong is configured to extend from the rearface of the body such that it is not visible from the front face of thebody after the face plate is secured to the fixture.
 32. The face plateof claim 28 wherein the at least one prong comprises at least one hookconfigured to engage an edge of the aperture after the prong is insertedto at least partially resist a removal force.
 33. The face plate ofclaim 32 wherein the at least one hook includes an inside taper thatallows the at least one hook to flex inward when a predetermined removalforce is applied so that the face plate can be selectively removed fromthe fixture without damaging the at least one prong.
 34. The face plateof claim 32 wherein the at least one hook is secured to the face plateby a flexible neck that allows at least one hook to deflect inward whenbeing inserted into the aperture.
 35. The face plate of claim 34 whereinthe at least one hook comprises a plurality of hooks, each hook beingsecured to the face plate by a separate flexible neck.
 36. The faceplate of claim 34 including a gap between the plurality of hooksconfigured to provide clearance that allows the plurality of hooks toflex inward when the at least one prong is inserted into the aperture.37. The face plate of claim 28 wherein the at least one prong comprisesa first prong for engaging a first flange of the fixture and a secondprong for engaging a second flange of the fixture.
 38. A deviceconfigured to be secured to a connection box, the device comprising: afixture including a main body and at least one flange extending from themain body, the at least one flange being used to secure the device tothe connection box; and a face plate configured to be secured to thefixture, the face plate including at least one prong that is configuredto be inserted into a face plate engagement aperture defined by the atleast one flange to secure the face plate to the fixture, wherein the atleast one prong is not visible from a front side of the face plate. 39.The device of claim 38 wherein the at least one flange further defines afixture securement aperture configured to receive a fastener forsecuring the fixture to the connection box.
 40. The device of claim 38wherein the fixture is a power receptacle and main body includes a firstelectrical socket and a second electrical socket.